Composition And Process For Manufacture Of A High Temperature Carbon-Dioxide Separation Membrane

ABSTRACT

A membrane composition and process for its formation are disclosed from the removal of carbon dioxide (CO 2 ) from mixed gases, such as flue gases of energy production facilities. The membrane includes a substrate layer comprising inorganic oxides, a barrier layer of in-situ formed Li 2 ZrO 3 , a Li 2 ZrO 3  sorbent layer and an inorganic oxide cap layer. The membrane has a feed side for introduction of mixed gases containing nitrogen (N 2 ) and a sweep side for recovery of CO 2  wherein the membrane has a relatively high selectivity for CO 2  transport at temperatures in the range of 400° to 700° C.

FIELD OF THE INVENTION

The present invention relates to a membrane composition and process for its formation which may then be employed for removal of carbon-dioxide (CO₂) such as the removal of CO₂ from flue gases of energy production facilities. The removal and capture of CO₂ may be accomplished at relatively high temperature and without the need for cooling flue gas thereby increasing the efficiency of carbon capture and sequestration.

BACKGROUND

Reduction in carbon dioxide (CO₂) emission from the coal-fired power plants has become a focal point of international efforts for climate control in recent years. Carbon dioxide emission from coal-fired power plants constitutes a relatively large portion (˜40%) of total CO₂ emissions. Developing a means to control coal-derived CO₂ emission is imperative in this effort; however, the cost for such carbon capture and sequestration (CCS) can be up to 50% of the energy production cost of a coal-fired power plant. A major portion of the penalty for CCS is the energy loss in cooling the flue gas (typically up to 750° C. exiting from the burner) to a lower temperature (100-300° C.), which the CO₂ separation system can tolerate. One reported method of reducing the energy penalty for CCS is to separate CO₂ at the existing flue gas temperature.

Relatively early studies of CO₂ capture with membranes indicated that the cost was 30% higher than the cost of the traditional amine chemical absorption process. The limitations of the studied membrane processes was identified as coming from the high cost of compressing low pressure flue gas and the low purity of the permeate, which resulted in the need for multistage processing to achieve the most economic arrangement for CCS in such systems. Recent analyses show that considerable CO₂ removal rates can be achieved with gas membrane separation systems, and the economic competitiveness of such systems in comparison with amine-based systems depends on the characteristics of both of membrane and feed gas. When membrane selectivity and permeability are improved, the CO₂ capture and total CCS costs may be reduced by up to 15% compared to the amine process.

CO₂ separation using membranes is a topic of great commercial interest with most of the reported membranes operating at relatively low temperatures. From the viewpoints of mechanism of separation and material stability, a growing need exists for membrane materials that are useful at temperatures of 400° C. or above.

SUMMARY

The present disclosure relate to a method of forming a membrane for separation of carbon dioxide (CO₂) from a mixture of gases comprising supplying a substrate layer of inorganic oxides with average pore sizes of 3.0 μm to 10.0 μm which is 20-80% porous with a thickness of 6.0 mm to 15 mm. One may then deposit on the substrate layer precursors for the formation of Li₂ZrO₃ and react the precursors and form a Li₂ZrO₃ barrier layer wherein the barrier layer is formed at a thickness of 10 μm to 100 μm with a porosity of 0% to 30%. One may then deposit on the barrier layer a sorbent layer comprising Li₂ZrO₃ at a thickness of 100 μm to 500 μm followed by deposition of a cap layer on the sorbent layer comprising inorganic oxides wherein the cap layer has a thickness of 50 μm to 250 μm. One may then expose such membrane to carbon dioxide at elevated temperatures (400° C. to 700° C.) and separate carbon dioxide from the gas mixture without the need for gas mixture cooling.

The present disclosure also relates to a membrane for separation of carbon dioxide (CO₂) from a mixture of gases comprising a substrate layer comprising inorganic oxides with average pore sizes of 3.0 μm to 10.0 μm which is 20-80% porous with a thickness of 6.0 mm to 15 mm; a barrier layer of in-situ Li₂ZrO₃ at a thickness of 10 μm to 100 μm with a porosity of 0% to 30%; a Li₂ZrO₃ sorbent layer at a thickness of 100 μm to 500 μm; and an inorganic oxide cap layer at a thickness of 50 μm to 250 μm. The membrane is configures such that it defines a feed side for introduction of mixed gases containing nitrogen (N₂) and a sweep side for recovery of CO₂ and the membrane has a selectivity a according to the following:

α=(Y _(A) /Y _(B))/((P _(h) X _(A) −P ₁ Y _(A))/(P _(h) X _(B) −P ₁ Y _(B)))

where Y_(A)=mole % CO₂ in the sweep side, X_(A)=mole % CO₂ in the feed side, P_(h)=backpressure in the feed side, X_(B)=mole % N₂ in the feed side; Y_(B)=mole % N₂ in the sweep side, and P₁=backpres sure in the sweep side; and wherein the value of α at 500° C. is in the range of 2.0 to 20.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features of this disclosure, and the manner of attaining them, may become more apparent and better understood by reference to the following description of embodiments described herein taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a cross-sectional view of the CO₂ separation membrane;

FIG. 2 is a composite microscopic view of the CO₂ separation membrane;

FIG. 3 is a SEM image of an uncoated substrate;

FIG. 4 is a SEM image of Li₂ZrO₃ deposited on the surface of the pores of the substrate;

FIG. 5 is a Thermogravimetric Analysis (TGA) showing CO₂ absorption kinetics of Li₂ZrO₃;

FIG. 6 is a SEM image illustrating a dense layer with pore size reduction and Li₂ZrO₃ filling of the pores;

FIG. 7 is a SEM image for dip coating formation of the dual phase sorbent layer 18 (FIG. 1) in a completed membrane.

FIG. 8 is a SEM image for chemical spay deposition of the dual phase sorbent layer 18 (FIG. 1) in a completed membrane.

FIG. 9 is a schematic of the test system to evaluate membrane performance.

FIGS. 10-11 are plots of the selectivity versus differential pressure for the indicated membranes.

FIGS. 12-13 are plots of selectivity versus temperature for the indicated membranes.

DETAILED DESCRIPTION

The present invention provides a membrane to separate CO₂ from, e.g., the flue gas of coal-fired power plants and similar hot sources, such as hydrogen production plants using a hydrocarbon steam reforming process, or any industrial processes that produce relatively large quantities of CO₂ at relatively high temperatures. The membranes herein are therefore configured to separate CO₂ from a given environment at temperatures at or above 400° C., and in the preferred range of 400° C. to 700° C.

Attention is directed to FIG. 1 which illustrates a preferred configuration for the CO₂ separation membrane. As can be seen, the membrane 10 may preferably be in tubular form 12 and may include an internal sweep within the tube to assist in CO₂ transport. The membrane is preferably sourced from inorganic oxide base substrate materials, such as ZrO₂, Al₂O₃, and lithium zirconate (Li₂ZrO₃) may then be applied as a solid absorbent to the substrate layer, as discussed further herein. Accordingly, the membrane preferably includes a substrate layer 14 of inorganic oxides which preferably has pores (openings) at an average pore size of 3.0 μm to 10.0 μm (linear dimension of the openings) and the substrate layer itself is preferably 20-80% porous. The substrate layer 14 may preferably have a thickness of 6.0 mm to 15 mm, and all values therein, in 0.1 mm increments. A more preferably thickness is in the range of 6.0 mm to 8.0 mm. This therefore provides what may be understood as a porous support layer containing lithium zirconate sorbent material.

A relatively thin and dense Li₂ZrO₃ barrier layer 16 is provided herein by in-situ procedures and presents a restriction to prevent any other gases except CO₂, if entered into a dual-phase sorbent layer 18 (described below) from transporting through the substrate by its relatively lower porosity than that of the dual phase sorbent layer as well as the optional use of selective eutectic carbonates layers on the Li₂ZrO₃. Barrier Layer 16 may therefore preferably have a thickness of 10 μm to 100 μm and a porosity form 0 to 30%

At relatively high temperature in the CO₂ environment, e.g. at temperature in the range of 400° C.-700° C. porous Li₂ZrO₃ sorbent may form a dual-phase layer 18 comprising a solid ZrO₂ framework and molten lithium carbonate (Li₂CO₃). Such dual-phase system may then only allow CO₂ to diffuse through and thus be transported while leaving the majority of any other gases behind. That is, 90% or more of gases other than CO₂ will not transport through the membrane 10, more preferably 95% or more, and in a most preferred configuration, 99% or more of the gases other than CO₂ will not transport through the membrane.

A porous ceramic ZrO₂ or Al₂O₃ cap layer 20 may be deposited on the dual phase sorbent layer 18 and used to improve the mechanical strength of the entire membrane system as well as serving as a protective coating to prevent other flue gas contaminants from entering into the membrane. Cap layer 20 may preferably have a thickness of 50 μm to 250 μm.

FIG. 2 provides a composite microscopic view of the membrane 10 herein. Layer 14 comprises the porous ZrO₂ and at 22 can be seen the region now infiltrated with liquid Li₂CO₃. The relatively dense Li₂ZrO₂ layer formed in-situ is again shown at 16 and the dual-phase sorbent layer is again identified at 18 along with porous cap layer 20.

It may now be noted that the CO₂ absorption and transport through the membrane is based in part on the reversible reaction of Li₂ZrO₃ and CO₂ as shown in the following:

Li₂ZrO_(3(s))+CO_(2(g))

Li₂CO_(3(I))+ZrO_(2(s))   [Eq. 1]

Furthermore, at high temperatures, such as temperatures in the range of 400-700° C., and under a certain CO₂ concentration in the flue gas, a steady-state reaction will be established and the CO₂ will be transported through the membrane containing Li₂ZrO₃, while other gases, such as N₂, being rejected.

In-Situ Formation of Li₂ZrO₃ Barrier Layer

As noted above, the substrate layer 14 may comprise an inorganic oxide such as porous zirconia oxide or porous alumina oxide. The preferred embodiment herein utilizes an in-situ formed Li₂ZrO₃ based barrier layer 16. The role of this layer is to serve as a final barrier against the penetration of gases other than CO₂ through the membrane. Layer 16 may control the rate of CO₂ transport as well as the efficiency of the CO₂ selectivity of the assembled membrane. It may preferably be formed within the porous ceramic substrate layer 14, with or without pore size reduction, via in-situ procedures, using chemical vapor deposition (CVD), physical vapor deposition (PVD), pressurized chemical infiltration, and similar processes.

CVD processes utilize appropriate precursor compounds for deposition of Li₂ZrO₃ coating via decomposition and activation of the precursor in an oxygen containing gaseous atmosphere. Reference to precursor compounds for Li₂ZrO₃ herein may be understood as one or more compounds which may react when deposited within the substrate 14 and form Li₂ZrO₃. In the CVD process the substrate temperature is established in the range of thermodynamically stable formation of Li₂ZrO₃ via a heterogeneous reaction between the reactive gas atmosphere and the substrate to be coated. Plasma assisted CVD processes using inductively coupled thermal plasma (ICTP) or electron cyclotron resonance (ECR) plasma heating can be utilized for further activation of the reactive vapor plasma environment, which allows reducing the deposition temperature and improving the coating density and morphology by reduction of the coating grains and producing ultra-fine coating morphology using deposition under relatively intense ion bombardment. In addition, plasma activation of the CVD process via ionization and excitation of atoms, molecules and radicals by collisions with excited particles and electrons allows depositing near stoichiometric coatings on substrates having temperatures below the temperature determined by thermodynamically equilibrated conditions of the coating material. This results in substantial reduction of coating stress due to thermal expansion mismatch between coating and substrate materials.

Turning to the pressed infiltration method, also referred to as press wet deposition, the precursors of Li₂ZrO₃, lithium nitrate (LiNO₃) and zirconia nitrate (ZrO(NO₃)₂), in stoichiometric ratios, are mixed in a solvent. A porous soft medium is saturated with the mixture and is placed on a substrate. The Li₂ZrO₃ precursors are then forced to infiltrate into the substrate by a rubber roller following by calcination at high temperatures, such as temperatures of 700° C. to 900° C., to again form in-situ Li₂ZrO₃ in the substrate.

Preferably, in order to obtain a relatively higher CO₂ absorption efficiency, Li₂ZrO₃ herein may also be modified to form a potassium doped sorbent in the formula of K_(x)Li_(2-x)ZrO₃, with an optimal crystalline structure. Reference to an optimum crystal structure may be best defined in terms of CO₂ absorption efficiency, and therefore, the crystal structure is configured such that the absorption by weight of the K_(x)Li_(2-x)ZrO₃ is such that is absorbs at or above 25% by weight CO₂, up to about theoretical absorption of 27.8% by weight. It should also be noted that the value of “x” in the indicated formula is in the range of 0.2-1.0.

The K-doped Li₂ZrO₃ yields eutectic carbonate mixtures of Li₂CO₃ and K₂CO₃ which will be in a molten stage at high temperature (to facilitate the diffusion of CO₂ for faster rate of CO₂ transport reaction). The optimal CO₂ absorption of the tetragonal crystalline phase is achieved by a calcination process.

The in-situ chemical synthesis of Li₂ZrO₃ according to the pressed infiltration method can be shown in the equation below. It should be noted that in the equation below, the addition of KNO₃ will readily provide the potassium doped sorbent noted herein.

2LiNO₃+ZrO(NO₃)₂→Li₂ZrO₃+2N₂O₅   [Eq. 2]

The Li₂ZrO₃ formed by the press infiltration method, according to the in-situ approach becomes physically attached to the inner pores of the substrates to provide for the boost in CO₂ separation disclosed herein. FIG. 3 shows the SEM of the uncoated substrate. FIG. 4 shows the SEM of the Li₂ZrO₃ crystals deposited on the surface of the pores in the substrate 14 by the press infiltration method. The kinetics of CO₂ absorption of the resulting Li₂ZrO₃ is comparable to Li₂ZrO₃ prepared by traditional solid state methods. See FIG. 5. In order for the membrane to possess the property of relatively high selectivity of CO₂ a relatively close encounter of CO₂ and Li₂ZrO₃ is preferably obtained for the chemical reaction to take place as shown above in Equation 1. The selectivity characteristics are discussed further below.

That is, preferably, to minimize the transport of gases other than CO₂, channels, open pores or voids in dense barrier layer 16 (see FIGS. 1 and 2) may be minimized to restrict the non-reactive flow of flue gas, which may be understood as a physical flux. Therefore, prior to the process of dense layer deposition, pore size reduction of the upper section of the substrate 14 may preferably be performed to assist in the maximum pore filling of Li₂ZrO₃ precursors to assist in the achievement of relatively low physical flux. Reference to upper section of the substrate is reference to the feature that for a given thickness of the substrate 14, the top ⅓ of such thickness including the surface layer may be understood as the upper section. Commercially available nanometer particle suspension solutions, such as ZrO₂ sol and organosilicate sols may therefore be applied to the substrate, by repeating dipping, drying, and sintering process. Reference to organosilicate may be understood as silica wherein a portion of the Si—O bonds have been replaced by organic groups. FIG. 6 presents a SEM image depicting a completed dense layer with no visible channels on the same substrate as shown in FIG. 3. That is, the upper section is such that it predominantly (50% or more) of the pores that may be present are less than or equal to 5.0 μm, more preferably, less than or equal to 1.0 μm. This process may therefore increase CO₂ contact with the Li₂ZrO₃ according to Equation 1 above.

Furthermore, a layer of eutectic mixture of Li₂CO₃:K₂CO₃ (80:20 mole ratio) may be preferably applied on the surface of the substrate 14 before application of layer 18 (see below). This layer may have a thickness of less than or equal to 10.0 μm, or in the range of 0.1-10.0 μm. It is also worth noting that such carbonates may preferably be prepared in an organic solvent as a suspension and applied on the substrate by repeating dipping sintering at the melting point to seal all the minor cracks and pinholes that might be formed during the process of providing dense barrier layer 16. Gas tightness may be evaluated before the presence of layer 18. A substrate layer 14 so treated with the referenced eutectic mixture may preferably have a gas flow through rate of close to 0%, +/−1.0% of that in the feed, and within the range of measurement sensitivity.

Layer 18 generally serves as the initial layer to retain CO₂ from the flue gas and minimize the entry of other gases. Layer 18 may preferably have a thickness of 100 μm to 500 μm. The CO₂ absorbed in layer 18 may build a high partial pressure as the driving force for CO₂ to travel through the membrane. Two deposition methods for producing layer 18 on barrier layer 16 may be employed, include dip coating and chemical spray deposition, as more fully described below. This also may provide for control of the particle sizes and thickness of the deposited Li₂ZrO₃.

Dip Coating

Synthesis of Li₂ZrO₃ sorbent with controlled particle size is preferred for layer 18 within the high temperature CO₂ separation membrane herein. A solid state method of preparing K-doped Li₂ZrO₃ with the optimal CO₂ absorption kinetics is preferably employed. It may be a mixture of reagent grade K₂CO₃, Li₂CO₃ and ZrO₂ solids of small particle sizes, in proper molar ratios, or a mixture of water solutions of K₂NO₃, LiNO₃ and zirconyl nitrate [ZrO(NO₃)₂.xH₂O], in proper molar ratios, and calcined at 700-800° C. to yield Li₂ZrO₃ sorbent in the favorable tetragonal phase. The particle size of the resulting solid sorbent may be further reduced to <1.0 μm by wet milling. Organic binder, such as polyvinyl alcohol (PVA) may be used to mix with the solid sorbent in water as a dip coating mixture. Dense layer coated substrate is manually dipped into the mixture for a specified time, typically 1 second, and dried at 80° C. The dipping and drying process is repeated 5-7 times before the product is then sintered. The particle size of Li₂ZrO₃ will be controlled by the particle size of starting ZrO₂, since during the calcination only ZrO₂ particles remain in a solid state due to its high melting point (2700° C.), while Li₂CO₃ forms a eutectic molten carbonate. The low calcination temperature applied, 700-800° C., favors the formation of the tetragonal phase for the optimal CO₂ absorption kinetics.

Chemical Spray Deposition

The precursors of Li₂ZrO₃, LiNO₃, KNO₃, and ZrO(NO₃)₂, in proper molar ratio, are dissolved in organic solvent and sprayed in fine droplets through an atomizing nozzle, with a stream of warm air, to deposit on the surface of the dense layer 16 deposited substrate at the boiling point of the solvents, approximately 60° C. After repeated spraying to reach the desired thickness, the spray-deposited ceramic substrates are then calcined in air. The calcination condition is the same as that for the dip coating process. The Li₂ZrO₃ sorbents formed in the spray coating has CO₂ absorption kinetics that are again comparable to that by solid state as shown in FIG. 5. The chemical spray deposition technique combines the formation and deposition of Li₂ZrO₃ in one step instead of two as in the dip coating method.

Outer Layer Deposition

The porous cap outer layer coating 20 can be optionally deposited on top of Li₂ZrO₃ sorbent layer 18 to further improve the structural integrity of the membrane at high temperature reactive interaction with CO₂. This coating having porosity ranging from 10 to 90% will consist of nonreactive ceramics such as alumina (Al₂O₃) or zirconia-based materials ZrO₂ or yttria-stabilized zirconia (YSZ). This layer preferably has a thickness ranging from 50 μm to 250 μm and may be deposited by high temperature high velocity powder plasma spray, HVOF, thermal spray, detonation (D-gun), CVD, or alternatively, by sol-gel, wet spray and other suitable powder application techniques followed by sintering in a suitable gas atmosphere at appropriate temperature and pressure. The SEM images of the cross section of a typical completely assembled membrane is shown in FIGS. 7 and 8 for dip coating and chemical spray deposition, respectively.

Membrane Performance

The performance of the membrane as a high temperature CO₂ separation membrane may be evaluated in a test system as shown in FIG. 9. Membranes may be evaluated at temperature of 400-630° C. under the conditions of anticipated flue gas in a coal-fired power plant; CO₂ of 10-20%, and differential pressure 0-5 psig. Selectivity of CO₂/N₂ and CO₂ permeability are the two parameters for measuring the effectiveness of a membrane as a CO₂ separator.

For the evaluation of the membranes, two parameters were measured: the CO₂ gas permeability and CO₂/N₂ selectivity. The quantity of CO₂ permeated through the membrane via various mechanisms is defined as the permeability or permeation:

Permeability (permeation)=(M _(p) ×F ₁×(P/(R×T))/(A×P ₁×60)   [Eq. 3]

in the units of mol⁻²s⁻¹ mPa, or

Permeability (GPU)=(((M _(p) ×F ₁×(P/(R×T))*V)/(A×P ₁×60))/(1 E−6)   [Eq. 4]

in the units of cm³(STP)cm⁻²s⁻¹cmHg⁻¹ as conventionally referred to as gas permeation unit (GPU)

where

-   -   M_(p)=Mole % of CO₂ in Sweep Side     -   F₁=Total flow rate of sweep gas, L/min     -   P=Sample pressure in GC sampling Loop, 1 atm=101325 Pa     -   R=Gas constant, 8314.472 P_(a)L K⁻¹ mol⁻¹     -   T=Temperature at Sample Loop, K     -   A=Membrane Area, 0.0011 m²     -   P₁=Backpressure in Sweep Side, mPa

The ability of a membrane to separate gases A and B is defined as Selectivity:

Selectivity(α)=(Y _(A) /Y _(B))/((P _(h) X _(A) −P ₁ Y _(A))/(P _(h) X _(B) −P ₁ Y _(B)))   [Eq. 5]

where

-   -   Y_(A)=Mole % CO₂ in Sweep Side     -   X_(A)=Mole % CO₂ in Feed Side     -   P_(h)=Backpressure in Feed Side     -   X_(B)=Mole % N₂ in Feed Side     -   Y_(B)=Mole % N₂ in Sweep Side     -   P₁=Backpressure in Sweep Side

In the literature, a more conventional expression of the separation of two gases through the membrane is called the membrane separation factor (S_(AB)), which is a measure of the quality of separation that the membrane provides:

S _(AB)=(Y _(A) /Y _(B))/(X _(A) /X _(B))   [Eq. 6]

When the sweep side pressure approaches to zero, i.e, P₁→0, the selectivity of the membrane for gases A and B is equal to the separation factor. In this disclosure, S_(AB) is used as the selectivity and the GC responses (the peak areas) of CO₂ and N₂ in the gas streams for the computation of permeability.

Membrane Testing Results

Tables 1 to 4 presents typical selectivity and permeability data for the assembled membranes herein illustrated generally in FIGS. 1 and 2 and evaluated under different conditions expected in a coal-fired power plant: CO₂ at 10-20% by volume, and the differential pressure between the feed and sweep (permeate) sides in 0-15 psig. Comparisons of the data are depicted in FIGS. 10 to 13. The selectivity values of CO₂/N₂ obtained are temperature and differential pressure dependent. A relatively high selectivity, 2 to 20 at 500° C. is observed.

TABLE 1 Selectivity and Permeability of Membranes - Performance under Various Differential Pressure between the Feed and Permeate Sides (Test Condition: CO₂ at 10.9% in N₂, 500° C.) Differential Pressure (psig) Membrane 0 5 10 15 CX2 Selectivity 6.89 5.00 3.16 2.51 Permeability (GPU) 25.7 37.7 53.3 65.6 CX3 Selectivity 20.0 12.3 10.1 8.81 Permeability (GPU) 24.8 38.9 46.4 56.9 Membranes: CX2: 50% porosity substrate with dip coating for layer 18 (FIG. 1). CX3: 50% porosity substrate with chemical spray coating for layer 18 (FIG. 1).

TABLE 2 Selectivity and Permeability of Membranes - Performance under Various Differential Pressure between the Feed and Permeate Sides (Test Condition: CO₂ at 18.8% in N₂, 500° C.) Differential Pressure (psig) Membrane 0 5 10 15 CX2 Selectivity 2.08 1.75 1.59 1.71 Permeability (GPU) 29.8 38.9 69.9 83.9 CX3 Selectivity 5.53 3.93 2.19 2.63 Permeability (GPU) 21.0 26.9 30.2 28.4 Membranes CX2: 50% porosity substrate with dip coating for layer 18 (FIG. 1).. CX3: 50% porosity substrate with chemical spray coating for layer 18 (FIG. 1).

TABLE 3 Selectivity and Permeability of Membranes - Performance at Various Temperature (Test Condition: CO₂ at 10.9% in N₂, Differential Pressure at 0 psig) Temperature (° C.) Membrane 400 500 600 630 CX2 Selectivity 3.63 6.89 5.45 5.43 Permeability (GPU) 16.0 25.7 32.9 28.1 CX3 Selectivity 2.25 20.0 11.3 19.0 Permeability (GPU) 12.0 24.8 27.3 26.9 Membranes CX2: 50% porosity substrate with dip coating for layer 18 (FIG. 1).. CX3: 50% porosity substrate with chemical spray coating for layer 18 (FIG. 1)..

TABLE 4 Selectivity and Permeability of Membranes - Performance at Various Temperature (Test Condition: CO₂ at 18.8% in N₂, Differential Pressure at 0 psig) Temperature (° C.) Membrane 400 500 600 630 CX2 Selectivity 1.33 2.08 5.67 5.17 Permeability (GPU) 15.7 29.8 29.1 29.9 CX3 Selectivity 0.89 5.5 10.3 16.0 Permeability (GPU) 12.6 21.0 26.8 26.0 Membranes CX2: 50% porosity substrate with dip coating for layer 18 (FIG. 1). CX3: 50% porosity substrate with chemical spray coating for layer 18 (FIG. 1).

The foregoing description of several methods and embodiments has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the claims to the precise steps and/or forms disclosed, and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto. 

1. A method of forming a membrane for separation of carbon dioxide (CO₂) from a mixture of gases comprising: supplying a substrate layer of inorganic oxides with average pore sizes of 3.0 μm to 10.0 μm which is 20-80% porous with a thickness of 6.0 mm to 15 mm; depositing on said substrate layer precursors for the formation of Li₂ZrO₃; reacting said precursors to form a Li₂ZrO₃ barrier layer wherein said barrier layer is formed at a thickness of 10 μm to 100 μm with a porosity of 0% to 30%; depositing on said barrier layer a sorbent layer comprising Li₂ZrO₃ at a thickness of 100 μm to 500 μm; depositing a cap layer on said sorbent layer comprising inorganic oxides wherein said cap layer has a thickness of 50 μm to 250 μm.
 2. The method of claim 1 wherein said precursors deposited on said substrate comprise LiNO₃ and ZrO(NO₃)_(2.)
 3. The method of claim 1 wherein said precursors deposited on said substrate are exposed to temperatures in the range of 700° C. to 900° C.
 4. The method of claim 1 wherein, prior to said deposition of said precursors, said substrate is treated with a nanoparticle suspension containing ZrO₂ or organosilicate compounds.
 5. The method of claim 1 wherein said substrate has a surface and an upper section comprising ⅓ of the thickness of said substrate wherein pores are present and wherein 50% or more of said pores in said upper section have a size of less than or equal to 5.0 μm.
 6. The method of claim 1 wherein a eutectic mixture of Li₂CO₃:K₂CO₃ is applied to said substrate prior to deposition of said sorbent layer comprising said Li₂ZrO₃.
 7. The method of claim 6 wherein said eutectic mixture is applied to provide a layer having a thickness of 0.1 μm to 10.0 μm.
 8. The method of claim 1 wherein said cap layer has a porosity of 10%-90%.
 9. The method of claim 1 wherein said cap layer comprises one of Al₂O₃, ZrO₂ or YSZ.
 10. The method of claim 1 wherein said Li₂ZrO₃ is formed in-situ is potassium doped and has the formula of K_(x)Li_(2-x)ZrO₃ where x has a value of 0.2-1.0.
 11. The method of claim 1 wherein said sorbent layer, upon exposure to carbon dioxide at temperatures of 400° C. to 700° C., results in the following reaction: Li₂ZrO_(3(s))+CO_(2(g))

Li₂CO_(3(I))+ZrO_(2(s)).
 12. The method of claim 11, wherein said reaction provides said sorbent layer as a dual-phase sorbent layer comprising solid ZrO₂ and molten Li₂CO₃.
 13. The method of claim 1 wherein said membrane has a feed side for introduction of mixed gases containing nitrogen (N₂) and a sweep side for recovery of CO₂ and said membrane has a selectivity a according to the following: α=(Y _(A) /Y _(B))/((P _(h) X _(A) −P ₁ Y _(A))/(P _(h) X _(B) −P ₁ Y _(B))) where Y_(A)=mole % CO₂ in the sweep side, X_(A)=mole % CO₂ in the feed side, P_(h)=backpressure in the feed side, X_(B)=mole % N₂ in the feed side; Y_(B)=mole % N₂ in the sweep side, and P₁=backpressure in the sweep side; and wherein said value of α at 500° C. is in the range of 2.0 to
 20. 14. A method of forming a membrane for separation of carbon dioxide (CO₂) from a mixture of gases comprising: supplying a substrate layer of inorganic oxides with average pore sizes of 3.0 μm to 10.0 μm which is 20-80% porous with a thickness of 6.0 mm to 15 mm; depositing on said substrate layer precursors for the formation of Li₂ZrO₃ comprising LiNO₃ and ZrO(NO₃)₂; reacting said precursors to form a Li₂ZrO₃ barrier layer at temperatures of 700° C. to 900° C. wherein said barrier layer is formed at a thickness of 10 μm to 100 μm with a porosity of 0% to 30%; depositing on said barrier layer a sorbent layer comprising Li₂ZrO₃ at a thickness of 100 μm to 500 μm; depositing a cap layer on said sorbent layer comprising inorganic oxides wherein said cap layer has a thickness of 50 μm to 250 μm; exposing said membrane to a mixture of gases containing carbon dioxide at temperatures of 400° C. to 700° C. and separating carbon dioxide from said mixture of gases.
 15. A membrane for separation of carbon dioxide (CO₂) from a mixture of gases comprising: a substrate layer comprising inorganic oxides with average pore sizes of 3.0 μm to 10.0 μm which is 20-80% porous with a thickness of 6.0 mm to 15 mm; a barrier layer of in-situ Li₂ZrO₃ at a thickness of 10 μm to 100 μm with a porosity of 0% to 30%; a Li₂ZrO₃ sorbent layer at a thickness of 100 μm to 500 μm; an inorganic oxide cap layer at a thickness of 50 μm to 250 μm; and wherein said membrane defines a feed side for introduction of mixed gases containing nitrogen (N₂) and a sweep side for recovery of CO₂ and said membrane has a selectivity a according to the following: α=(Y _(A) /Y _(B))/((P _(h) X _(A) −P ₁ Y _(A))/(P _(h) X _(B) −P ₁ Y _(B))) where Y_(A)=mole % CO₂ in the sweep side, X_(A)=mole % CO₂ in the feed side, P_(h)=backpressure in the feed side, X_(B)=mole % N₂ in the feed side; Y_(B)=mole % N₂ in the sweep side, and P₁=backpressure in the sweep side; and wherein said value of α at 500° C. is in the range of 2.0 to
 20. 16. The membrane of claim 15 wherein said barrier layer contains LiNO₃ and ZrO(NO₃)₂ precursors which provide said Li₂ZrO_(3.)
 17. The membrane of claim 15 wherein said Li₂ZrO₃ is potassium doped and has the formula of K_(x)Li_(2-x)ZrO₃ where x has a value of 0.2-1.0. 